help with aviation fuel cap fittment to vz ss utility

[mattyp503]

hello i am fitting an aviation fuel cap to my vz ute but require some in depth drawing of the overall inner fuel cap dimensions! i have the aviation fuel cap which sits flush in the circular mounting however i cannot find the appropriate information on the net i require the depth and width etc and also the size of the existing fuel neck which will have to be modified in order to get a gland to fit from the new fuel cap to the fuel tank neck so my fuel doesnt evapourate away Can anybody help me????

[SINISTER R8]

why bother at all??? wouldnt the aviator fuel cap still be behind the factory body fuel flap thingo, and no one will see it??? or am i completley off track on this one?

[mattyp503]

u would definately see the cap of the aviation fuel cap but my concern is when i go to fill up with fuel as the neck of the new cap does not connect to the old inner cap ! the fuel flap will be removed as well which would leave the nice polished aluminium aviation fuel cap

[gavlotic]

i think there was a guy that had a sparco one on the ute pic thread...

[mattyp503]

do u have a

do u have a quick link for that? the information i really need is the actual inner fuel cap dimensions along with the fuel tank neck dimensions but i cant seem to find that information on the net anywhere havent tried holden yet though

[white lie]

Can't you just measure it off the thread on the cap?
Earl's stock heaps of different sizes and pretty sure they do adaptor necks as well... Perhaps this is of some help?

http://www.earls.com.au/files/496439d2ce1ae-NEWTONFILLERCAPSCATALOGUEJAN2008.PDF

[mattyp503]

yes that is of help for the fuel cap which i have bought but i need the physical measurements of the actual existing fuel tank cut in on the body of the car as i have to get a insert made to bolt the aviation fuel cap onto (this is not the problem) however i need to get a gland or nipple engineered in order to get the neck of the aviation fuel cap to the neck of the fuel tank!! this is my main problem as measuring the requirements for this gland will be virtually impossible as you cannot see behind the aviation cap when its fitted and by taking the center out of the aviation fuel cap doesnt allow any room for accurate measurement this is my dilemma !! if i had the actual measurements of the original fuel insert i.e circumference, depth, height of fuel tank neck etc etc it would be most possible to make one only i lack these measurements for the fabricator to undertake this task!!

[NefariousLS1]

cant u just remove the rubber insert and the inner panneling to measure and photograph it urself?

[mattyp503]

yes i could but that still doesnt allow for the actual behind the aviation cap measurements the fabricator prefers to have a factory drawing of this information in order to have correct measurements like the actual information from earls website for the newton fuel caps which i have already http://www.earls.com.au/files/496439d2ce1ae-NEWTONFILLERCAPSCATALOGUEJAN2008.PDF in order to calculate what is required i feel this information would make the process easier for the fabricator! does this information exist and is it availiable ?

[white lie]

I don't think they'd (Holden) would even have measurements for it. They will have exploded diagrams for parts but its highly unlikely to have any measurements on it. Sorry to say it, but I think you'll have to do the leg work on your own here.

[mattyp503]

that is exactly what i didnt want to hear !!! oh well if thats the facts then i guess i have no options but to try and measure the dimensions with the fabricator ! the job could get messy but alas thats the way it goes i suppose:bawl:!!! thanks for your time and help anyhows

[MJR-57T]

Cut the guts out of the standard filler area so that all thats left is a hole with a pipe in it.
From memory its a 2" pipe from the tank to the filler.

make sure you cut iff off after the breather and just extend the 2" rubber pipe out and attach it to your avation filler.

Its not that hard

[mattyp503]

i assume you mean cut out the metal surrounding the fuel neck and then cut the fuel neck to expose the fuel neck pipe minus the cap holder? is that correct then how do you bolt in the aviation cap?? im a little confused as the new cap sits in the fuel cap area please explain futher thankyou

[MJR-57T]

basically you need to somehow connect the tank to the avation fual cap via a good seal.

This may mean totally removing the existing pipe and filler neck just leaving the sheet metal hole in guard.

Connect a piece of 2" (or what ever sixe it is) pipe from the bottom of your new filler to the tank inlet. you might need to cut an inch for 2 of the bottom of the filler so that it fits in the hole
Make all the connections to the filler first, slide it all through the hole with the connection to the tank last.

Your only headache will be the breather hose.
A simple fix would be to cut the section where the breather plugs onto the filler hose out of the existing filler neck, leaving a few inches either side to allow it to be connected somewhere inline with the rubber filler hose.

If thats too much, i cant really help you anymore untill you go pull everything apart and see what needs to be done for yourself.
Or go the the wreckers and suss out a wrecked one



EDIT

Ok i sorta have an idea where your comming from after reading back through it again

If you can use the avation filler top only and keep shaving the pipe off the bottom mm by mm untill it sits flush.
You should be able to stick the bowser nozzle in through both holes without spilling anything.
Only problem will be weather or not the you can make up a gasket that goes around the bottom of the filler neck on the avation filler so that you dont end up with a constant puddle in the filler bay because of splash back.

Good luck

[mattyp503]

yes thats right that is my main concern as the aviation cap has a four inch neck (newton aero 500) and the fuel tank neck is two inch, unfortunately the existing fuel cap neck sits too high to get the aviation cap in place so one or the other would have to be trimmed to allow a gland to fit over !! :bawl: